Enclosure Device for Concrete Column Formwork

ABSTRACT

An enclosure device for a concrete column formwork uses an envelope comprising a tubular wall portion and a top portion supported on the formwork such that the wall portion extends about a perimeter of the column formwork and extends vertically along a height of the column formwork and such that the top portion encloses a top end of the wall portion. The envelope also has brace openings to receive formwork braces extending therethrough and slots in the envelope communicating between the brace openings and a bottom edge of the wall portion so that the envelope can be lowered downwardly over the column formwork as the braces are inserted upwardly through the slots into the brace openings.

This application claims foreign priority benefits from Canadian Patent Application No. 3,148,867 filed Feb. 15, 2022.

FIELD OF THE INVENTION

The present invention relates to an enclosure for surrounding a concrete formwork to protect the concrete in the formwork from cold weather, and more particularly the present invention relates to a concrete formwork enclosure that is particularly suited for mounting over formwork for forming a concrete column.

BACKGROUND

When forming concrete, concrete is typically poured into a form and then cured. In colder climates, care must be taken to prevent freezing of the concrete during the curing process to ensure that the concrete is not weakened or improperly cured. In some instances, this is accomplished by assembling tarps to form an enclosure about the concrete form that can be heated. When the concrete form is a column requiring braces to support the column formwork, it can be very awkward and time consuming to position the tarps to form an adequate enclosure about the formwork.

SUMMARY OF THE INVENTION

According to one aspect of the invention there is provided a method of enclosing a concrete column formwork comprising:

providing an envelope comprising a tubular wall portion and a top portion; and

supporting the envelope on the concrete column formwork such that the wall portion extends about a perimeter of the column formwork and extends vertically along a height of the column formwork and such that the top portion encloses a top end of the wall portion.

The method may further comprise (i) suspending the wall portion of the envelope from a top end of the concrete column formwork, and (ii) providing rigid supports supported on the wall portion of the envelope that extend generally in a circumferential direction about the perimeter of the column formwork at different heights along the column formwork.

When the formwork includes form walls extending upwardly from a supporting structure and braces extending laterally outwardly from the form walls for connection to the supporting structure, the method may further include (i) providing a plurality of brace openings in the envelope to receive the braces extending therethrough and slots in the envelope communicating between the brace openings and a bottom edge of the wall portion, and (ii) lowering the envelope downwardly over the column formwork such that the braces are inserted upwardly through the slots into the brace openings respectively.

According to a second aspect of the present invention there is provided an enclosure device for curing concrete in a column formwork, the device comprising:

an envelope sized and shaped to surround the column formwork;

the envelope comprising (i) a wall portion arranged to extend in a circumferential direction about a perimeter of the column formwork and extend vertically along a height of the column formwork and (ii) a top portion arranged to enclose a top end of the wall portion.

The enclosure device and the method of use of the enclosure device allow a concrete column formwork to be enclosed for insulation from weather and/or for heating to ensure that the concrete can adequately cure in cold temperatures, in a manner that is easier and more reliable to deploy about the concrete column formwork as compared to conventional construction tarps.

The wall portion is tubular in shape having an open bottom end arranged to receive the column formwork therein as the envelope is lowered onto the column formwork.

When the column formwork includes a plurality of braces extending laterally outward from the formwork for connection to adjacent structures, the device may further comprise a plurality of brace openings formed in the wall portion at respective brace locations to receive the braces extending therethrough respectively. Each brace opening may further comprise a slot formed in the wall portion in communication between the brace opening and an open bottom of the wall portion of the envelope.

The top portion of the envelope is operable between a closed position enclosing the top end of the wall potion and an open position in which the top end of the wall portion is open so as to allow access for pouring concrete into the concrete formwork through the open top end.

The top portion of the envelope may comprise a tubular extension of the wall portion in which the tubular extension is formed of pliable material arranged to be cinched together at a central location above the wall portion.

Alternatively, the top portion of the envelope may comprise a top panel hinged on the wall portion along a first side of the top panel for pivotal movement between the open position and the closed position thereof. In this instance, the top panel may further comprise a plurality of connecting flaps protruding from a perimeter of the top panel so as to be arranged to be mounted in overlapping arrangement with the wall portion of the envelope in the closed position.

The device preferable further includes at least one rigid support member supported on the wall portion of the envelope at each one of a plurality of different elevations along the height of the envelope. When the wall portion of the envelope has a polygonal perimeter shape, the at least one rigid support member at each different elevation may comprise one rigid support member extending along each side of the polygonal perimeter shape such that the support members extend substantially fully about the perimeter of the concrete formwork. Preferably, each rigid support member is received within a respective pocket formed in the wall portion of the envelope. Each pocket is preferably externally accessible such that the rigid support members are removable from the envelope from an exterior of the envelope.

The envelope is preferably formed of a pliable sheet material including one or more woven plastic layers and a heat insulating layer lining the one or more woven plastic layers.

The device may further include at least one vent opening formed in the envelope.

The vent opening may include a vent panel at least partially covering the vent opening.

According to the illustrated embodiment the wall portion of the envelope has a rectangular perimeter shape fitted onto the column formwork.

The device may further include a mounting arrangement arranged to couple the top end of the envelope to the formwork such that the wall portion is suspended from the top end of the wall portion about the formwork.

BRIEF DESCRIPTION OF THE DRAWINGS

One embodiment of the invention will now be described in conjunction with the accompanying drawings in which:

FIG. 1 is perspective view of a first embodiment of the enclosure device;

FIG. 2 and FIG. 3 are front and side elevational views of the enclosure device according to the first embodiment of FIG. 1 ;

FIG. 4 is a top plan view of the enclosure device according to the first embodiment of FIG. 1 ;

FIG. 5 is an enlarged side elevational view of a portion of the enclosure device according to the first embodiment of FIG. 1 ;

FIG. 6 is an end view of one of the pockets on the enclosure device;

FIG. 7 is a partly sectional view of a concrete column within concrete column formwork that is surrounded by the enclosure device;

FIG. 8 is perspective view of a second embodiment of the enclosure device;

FIG. 9 and FIG. 10 are front and side elevational views of the enclosure device according to the second embodiment of FIG. 8 ;

FIG. 11 is a top plan view of the enclosure device according to the second embodiment of FIG. 8 ; FIG. 12 is an enlarged side elevational view of a portion of the enclosure device according to the second embodiment of FIG. 8 ;

FIG. 13 and FIG. 14 are perspective views of the top portion of the envelope shown in open and closed positions for use with the enclosure device according to the second embodiment of FIG. 8 ;

FIG. 15 is a perspective view of the top portion of the envelope shown in a closed position, for use with any of the enclosure devices described herein.

In the drawings like characters of reference indicate corresponding parts in the different figures.

DETAILED DESCRIPTION

Referring to the accompanying figures there is illustrated a concrete column formwork enclosure device generally indicated by reference numeral 10.

The device 10 is particularly suited for use with formwork 12 for forming a concrete column 14. In the illustrated embodiment, the formwork 12 generally includes a plurality of wall panels 16 defining the boundaries of the cavity receiving concrete poured therein. More particularly, a set of four wall panels 16 are provided at the four sides of the formwork when forming a square concrete column. In this manner the wall panels 16 extend about the full perimeter of the concrete receiving cavity so as to be tubular in shape while spanning the full height of the desired column to be formed by the formwork. A plurality of frame members 18 are mounted about the exterior of the wall panel 16 to surround and support the wall panels at the boundary of the concrete receiving cavity. The bottom end of the tubular structure formed by the wall panel 16 typically comprises a suitable horizontal supporting surface of a supporting structure 20 upon which the concrete column is to be formed.

In the illustrated example, a plurality of braces 22 are joined between the wall panels and the supporting structure 20 to provide additional support to the wall panels. Each brace extends laterally outwardly at a downward slope from an elevated location on the wall panels to the supporting structure. When forming a concrete column in the range of 20 to 24 feet in height with cross-sectional dimensions in the order of 2 to 3 feet or less, only two adjacent sides of the formwork 12 may include braces 22 joined to the wall panels thereof in which each corresponding side of the formwork includes two laterally spaced apart braces joined to the wall panel at a first elevation (for example between 1 and 2 feet from the bottom of the formwork) and two laterally spaced apart braces joined to the wall panel at a second elevation (for example between 9 and 10 feet from the bottom of the formwork). When locating the braces on two adjacent sides of the formwork, the braces on one side extend laterally outwardly from the formwork in a direction which is perpendicular to the braces on the adjacent side of the formwork for stiffening and supporting the column formwork in two perpendicular directions relative to the supporting structure 20.

Alternatively, when using formwork for larger diameter columns, for example near 6 feet in cross-sectional dimension, it may be preferably to use braces on each of the four sides 28 of the formwork in which the braces 22 on each wall panel 16 are arranged substantially as described above.

The device 10 generally comprises an envelope formed of a flexible, pliable, sheet material. The material forming the envelope may include one or more layers of a woven plastic material, for example polyethylene fabric formed of strands of polyethylene that are cross woven, reinforced and coated for waterproofing and ultraviolet resistance, and one or more layers of a heat insulating material, for example a flexible foam sheet layer. In a preferred arrangement, one layer of heat insulating material is bonded between external layers of plastic material to form the overall sheet material used in defining the boundaries of the envelope.

The envelope is typically shaped and sized to define (i) a wall portion 24 that is generally tubular in shape to extend fully about the perimeter of the formwork 12 and also span the full height of the formwork between top and bottom ends thereof, and (ii) a top portion 26 that encloses the open top end of the wall portion 24. The top portion 26 is typically operable between a closed position fully enclosing the top end of the wall portion 24 and an open position in which the top end of the wall portion is substantially unobstructed by the top portion 26 for example to enable pouring of concrete into the open top end of the formwork 12.

In the illustrated embodiments, the wall portion 24 is polygon or square in shape so as to match the perimeter shape of the formwork. In the instance of a square column, the wall portion is formed to include four sides 28 which are shaped and sized to be slightly larger than the dimensions of a corresponding wall panel 16 of the formwork. The four sides 28 are integrally joined or sewn together to extend continuously about the perimeter of the formwork in the circumferential direction of the column. The top and bottom ends of the tubular wall portion 24 may remain open.

In the illustrated embodiment according to FIG. 1 , two adjacent sides 28 of the wall portion are provided with brace openings 30 formed therein to be located in alignment with the mounting locations of the corresponding braces 22 on two of the wall panels 16 of the formwork. Alternatively, according to the embodiment of FIG. 4 , all sides 28 of the wall portion 24 may be provided with brace openings 30 formed therein in alignment with the mounting locations of the braces 22.

In each instance two brace openings 30 are formed in each of the relevant sides 28 of the wall portion at laterally spaced apart at the second elevation of the braces on the formwork. Slots 32 are also formed in the relevant sides 28 of the wall portion 24 to connect vertically downward from the brace openings 30 to the bottom edge of the corresponding side 28 of the wall portion 24. The slots 32 are thus also aligned with the lower braces at the first elevation on the formwork to receive the braces therethrough in a mounted position of the envelope onto the formwork. The slots 32 allow the corresponding braces to be received within the brace openings 30 or an intermediate portion of the slot 32 functioning as a brace opening for the lowermost braces by inserting the braces upwardly through the respective slots 32 as the envelope is lowered downwardly over top of the formwork 12 in use.

Suitable closures 34 are associated with each slot for closing the slot once the envelope has been mounted about the formwork. In the illustrated embodiment the closures 34 comprise grommets mounted within respective openings in the sheet material of the envelope to allow fastener ties to be fastened through a pair of grommets at opposing sides of the slot 32 so that the ties span across the seam and close the seam of the slot 32 at the fasting location. Plural sets of closures 34 at different elevations are provided along each slot 32. In alternative embodiments, closure flaps may be secured along one side of the slot 32 for bridging across the seam of the slot and fastening to the sheet material on the opposing side of the slot using various fasting techniques including grommets with ties or use of hook and loop fasteners for example.

The envelope further includes a plurality of pockets 36 supported at different elevations or heights spaced vertically apart from one another along each of the four sides 28 of the wall portion. Each pocket 36 comprises a tube of fabric material which is sewn onto the exterior of the fabric material of the envelope to extend horizontally between two opposing open ends of the pocket 36. Each pocket 36 is thus externally accessible so as to be arranged to accept a rigid support member 38 inserted therein or removed therefrom from the exterior of the envelope. Each pocket 36 spans nearly the full width in the horizontal direction of the corresponding side 28 of the wall portion upon which it is supported. Along each side wall, the pockets 36 are mounted at designated elevations similar to the other sides 28. In this manner, at each designated elevation (for example at 3, 9, 15, and 21 feet from the bottom in the illustrated embodiment) a set of four pockets 36 on the four sides 28 respectively collectively extend about the full perimeter of the wall portion.

Each pocket is suitably sized to receive rigid support member 38 such as a section of dimensional lumber for example a piece of lumber designated as 2″×4″ in cross-section, or alternatively a section of commercially available ABS or PVC pipe commonly available in diameters ranging from 1 inch to 3 inches for example. The rigid support members are typically sized to span the width of the corresponding side 28 of the wall portion. Connectors may be used at the corners of the wall portion 24 so that the rigid support members 38 on all sides of the wall portion at each designated location may be further joined together to extend continuously about the perimeter or circumference of the envelope. The rigid support members 38 primarily act to maintain the shape of the envelope relative to the formwork. When the envelope is shaped to provide a small gap between the exterior of the wall portion and the interior of the envelope, the rigid support members thus further act to maintain a substantially even gap about the perimeter of the formwork. When the wall portion of the envelope is suspended from a top end of the wall portion connected to the top end of the formwork, the rigid support members 38 within the pocket 36 are in turn typically entirely supported by being suspended on the sheet material forming the wall portion 24 of the envelope.

The particular size and dimensions of the wall portion can be varied according to the formwork. For example, the embodiment shown in FIGS. 1 through 7 has sides 28 of the wall portion 24 that each span approximately 3 feet between adjacent sides. The embodiment shown in FIGS. 8 through 14 has sides 28 of the wall portion 24 that each span approximately 6 feet between adjacent sides. In yet further embodiments, the dimensions can be further modified according to the column being formed by the formwork.

The top portion 26 of the envelope may take various forms. For example as shown in the embodiment of FIG. 1 , the sheet material forming the envelope can also be shaped and sewn into a pyramid form having four triangular panels 40 which extend upwardly from the four sides 28 of the wall portion to be joined together at a central apex from which the envelope can be suspended, for example when lowering the envelope over top of the formwork. One or more of the seams between the adjacent panels could optionally be secured with releasable closures to enable the top portion to be opened and closed for access as required. When lowering the envelope over top of formwork that has already received concrete poured therein, the top portion 26 may be permanently closed by sewing the panels to one another.

Alternatively as shown in the embodiment of FIG. 8 , the top portion may comprise a flat top panel 42 which is sized to span horizontally across the open top end of the wall portion in the closed position. The top panel 42 in this instance is a square panel having four edges corresponding to the four sides 28 of the wall portion. In this instance one of the side edges of the top panel 42 may be coupled to a corresponding one of the sides 28 of the wall portion by being fastened or connected in a manner that the top panel is hinged to the wall portion for movement between the open and closed positions relative to the wall portion. Additional connecting flaps 44 can be secured along the remaining edges of the top panel 42 so that the connecting flaps overlap external surfaces at the top of the remaining sides 28 of the wall portion in the closed position. Suitable closures 46 such as hook and loop fasteners or grommets that receive ties secured therethrough when fastened to corresponding grommets on the wall portion can be used for securing the top panel in the closed position.

In a further embodiment, the top portion 26 of the envelope may comprise a tubular extension 48 of the wall portions 24 of the envelope, shown in FIG. 15 in an open position in broken line and in a closed position in solid line. In this instance additional sheet material is provided above the top end of the formwork which can be cinched or gathered together towards a central apex to close the top portion. In this instance grommets may be provided at spaced positions about the top end of the tubular extension 48 to receive a suitable cord threaded therethrough which functions to tie or gather the tubular extension at a central apex.

In each instance, the top portion of the envelope is arranged to span across the top end of the formwork and may be sufficiently strong in the closed position so that the engagement of the top portion on the top end of the formwork provide sufficient structural support to suspend the weight of the wall portion 24 of the envelope and the rigid support members 38 suspended thereon from the top end of the envelope on the formwork.

As shown in FIG. 7 , a plurality of vent openings 50 may also be provided at various spaced apart locations within the wall portion 24 or top portion 26 of the envelope. In some examples the vent openings 50 may comprise small openings defined by grommets mounted within the sheet material.

Alternatively, as also shown in FIG. 7 , the vent openings 50 may comprise larger openings or slots formed through the sheet material in alignment with a covering panel 52 overlapping the exterior of the sheet material at the vent opening while being joined to the wall portions such that a bottom edge remains disconnected and in open communication with the vent opening being covered. For example, the covering panel 52 may form an exterior pocket which is open to the bottom edge thereof while locating the respective vent opening 50 within the pocket to allow ventilation through the vent opening while preventing entry of precipitation.

Use of the enclosure device 10 typically starts by selecting an appropriately sized envelope that matches the concrete column formwork 14 so as to span the full height of the formwork and so as to extend about the full perimeter of the formwork by closely matching the perimeter shape with a substantially even gap between the exterior of the formwork in the inner boundary of the envelope. The envelope is suspended from the top portion thereof, for example by suspending the envelope from an overhead crane or lift so that the bottom end of the envelope can be aligned with the top of the formwork for subsequent lowering of the envelope onto the formwork. The envelope is lowered until the top end of the envelope is engaged upon the top end of the formwork and the bottom end of the envelope engages the supporting surface upon which the bottom end of the formwork is supported. The slots 32 remain open as the envelope is inserted over top of the formwork such that the braces are inserted upwardly through the slots into the respective brace openings in the envelope. The slots 32 in the wall portion of the envelope can then be closed using appropriate closures 34 such that the braces remain protruding from respective ones of the brace openings in the envelope.

The top portion 26 can remain open to allow pouring of concrete into the open top end of the formwork subsequent to placement of the envelope about the formwork, followed by closing of the top portion to retain heat within the formwork during curing of the concrete.

Alternatively, when the concrete is already poured into the formwork before placement of the envelope, the top portion can be closed and remain closed as the envelope is placed over top of the formwork.

The enclosure device 10 may be used simply to protect the concrete from the weather without any external heating being provided by relying on the exothermic reaction of the curing concrete to sufficiently heat the interior space within the enclosure. Alternatively in colder climates, an external heater they be used to direct heated air into the enclosure for maintaining the concrete within the formwork above a prescribed temperature while curing the concrete.

Since various modifications can be made in the invention as herein above described, and many apparently widely different embodiments of same made, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense. 

1. An enclosure device for curing concrete in a column formwork, the device comprising: an envelope sized and shaped to surround the column formwork; the envelope comprising (i) a wall portion arranged to extend in a circumferential direction about a perimeter of the column formwork and extend vertically along a height of the column formwork and (ii) a top portion arranged to enclose a top end of the wall portion.
 2. The device according to claim 1 wherein the wall portion is tubular in shape having an open bottom end arranged to receive the column formwork therein as the envelope is lowered onto the column formwork.
 3. The device according to claim 1 wherein the column formwork includes a plurality of braces extending laterally outward from the formwork for connection to adjacent structures, the device further comprising a plurality of brace openings formed in the wall portion at respective brace locations to receive the braces extending therethrough respectively.
 4. The device according to claim 3 wherein each brace opening further comprises a slot formed in the wall portion in communication between the brace opening at the brace location and an open bottom of the wall portion of the envelope.
 5. The device according to claim 1 wherein the top portion of the envelope is operable between a closed position enclosing the top end of the wall potion and an open position in which the top end of the wall portion is open so as to allow access for pouring concrete into the concrete formwork through the open top end.
 6. The device according to claim 5 wherein the top portion of the envelope comprises a tubular extension of the wall portion, the tubular extension being formed of pliable material arranged to be cinched together at a central location above the wall portion.
 7. The device according to claim 5 wherein the top portion of the envelope comprises a top panel hinged on the wall portion along a first side of the top panel for pivotal movement between the open position and the closed position thereof.
 8. The device according to claim 7 wherein the top panel further comprises a plurality of connecting flaps protruding from a perimeter of the top panel so as to be arranged to be mounted in overlapping arrangement with the wall portion of the envelope in the closed position.
 9. The device according to claim 1 further comprising at least one rigid support member supported on the wall portion of the envelope at each one of a plurality of different elevations along the height of the envelope.
 10. The device according to claim 9 wherein the wall portion of the envelope has a polygonal perimeter shape, the at least one rigid support member at each different elevation comprising one rigid support member extending along each side of the polygonal perimeter shape such that the support members extend substantially fully about the perimeter of the concrete formwork.
 11. The device according to claim 9 wherein each rigid support member is received within a respective pocket formed in the wall portion of the envelope.
 12. The device according to claim 11 wherein each pocket is externally accessible such that the rigid support members are removable from the envelope from an exterior of the envelope.
 13. The device according to claim 1 wherein the envelope is formed of a pliable sheet material including one or more woven plastic layers and a heat insulating layer lining the one or more woven plastic layers.
 14. The device according to claim 1 further comprising at least one vent opening formed in the envelope.
 15. The device according to claim 14 further comprising a vent panel at least partially covering said at least one vent opening.
 16. The device according to claim 1 wherein the wall portion of the envelope has a rectangular perimeter shape fitted onto the column formwork.
 17. The device according to claim 1 further comprising a mounting arrangement arranged to couple the top end of the envelope to the formwork such that the wall portion is suspended from the top end of the wall portion about the formwork.
 18. A method of enclosing a concrete column formwork comprising: providing an envelope comprising a tubular wall portion and a top portion; and supporting the envelope on the concrete column formwork such that the wall portion extends about a perimeter of the column formwork and extends vertically along a height of the column formwork and such that the top portion encloses a top end of the wall portion.
 19. The method according to claim 18 further comprising: suspending the wall portion of the envelope from a top end of the concrete column formwork; and providing rigid supports supported on the wall portion of the envelope that extend generally in a circumferential direction about the perimeter of the column formwork at different heights along the column formwork.
 20. The method according to claim 18 wherein the formwork includes form walls extending upwardly from a supporting structure and braces extending laterally outwardly from the form walls for connection to the supporting structure, the method further comprising: providing a plurality of brace openings in the envelope to receive the braces extending therethrough and slots in the envelope communicating between the brace openings and a bottom edge of the wall portion; and lowering the envelope downwardly over the column formwork such that the braces are inserted upwardly through the slots into the brace openings respectively. 